Browse Topic: Braking systems

Items (5,460)
Pedestrians are among the most vulnerable participants in traffic, particularly when crossing the road. Extensive research has been conducted globally on the yielding behavior analysis of vehicle–pedestrian interaction and the design of automatic vehicle braking systems to mitigate pedestrian casualties. However, few studies have comprehensively addressed lateral risks using implicit kinematic cues in pedestrian–vehicle interactions. Moreover, the design of collision avoidance systems has rarely taken into account driving behavior, along with the pedestrian’s kinematics and crossing behavior. This article presents a human-like automatic braking fuzzy control strategy for pedestrian–vehicle collision avoidance, combining the advantages of professional driver emergency braking behavior and kinematic interaction cues. First, a high-fidelity driving simulator is used to investigate the yielding behavior of pedestrian–vehicle interaction when pedestrians cross the road. Second, the
Zhang, WenyanHuang, XiaorongSun, ShuleiFu, KairongXiong, QingHuang, Haibo
This paper presents a novel sensitivity analysis framework for differential braking as a backup steering solution in fail-operational Steer-by-Wire systems. The fault-tolerant design approach of Steer-by-Wire and steering systems for highly automated driving relies on the availability of road wheel actuators (RWA). Redundancies are therefore commonly used to ensure fail-operationality. Since its widespread implementation in production vehicles through electronic stability control, the use of differential braking as a cost-effective measure is desirable to increase functional diversity. However, feasible lateral accelerations through this backup solution are limited compared to conventional steering systems and lie close to ordinary driving scenarios. To address this limitation, this work investigates the influence of chassis parameters on differential braking performance. After defining characteristic values and a simulation test plan, a preliminary analysis using a linear single-track
Salzwedel, LeonIatropoulos, JannesHeise, CedricFrohn, ChristianHenze, Roman
This SAE Recommended Practice provides a common method to measure wear of friction materials (brake pad assemblies and brake shoes) and their mating parts (brake disc or brake drum). These wear measurements apply to brakes fitted on passenger cars and light trucks up to 4536 kg of Gross Vehicle Weight Rating under the Federal Motor Vehicle Safety Standard (FMVSS), or vehicles category M1 (passenger cars up to nine occupants, including the driver) under the European Community’s ECE Regulations.
Brake Dynamometer Standards Committee
Wheel-corner brake failures can significantly deteriorate vehicle stability and safety, since unbalanced braking forces may introduce an undesired yaw moment. This work investigates a fault-tolerant control strategy for Active Wheel-Corner Systems, exploiting Four-Wheel Independent Steering (4WIS) to mitigate such effects and preserve vehicle stability when brake actuator malfunctions occur. Unlike many existing approaches, the proposed framework does not require explicit fault detection or quantification as a prerequisite for corrective action, eliminating potential delays and uncertainties associated with fault-diagnosis schemes. A reference model for yaw rate and sideslip angle, incorporating combined longitudinal and lateral dynamics, is proposed, and a Weighted Pseudo-Inverse Control Allocation (WPCA) scheme is employed to distribute corrective actions among the four steering angles according to each tire’s capability, compensating for yaw moment imbalances caused by degraded
Sonnino, SamuelMelzi, StefanoCaresia, PietroManzoni, AlessandroVaini, Gianluca
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a
D R, RajkumarO, Vivin LeninR, SaktheevelR G, Ajay KrishnaNg, Bhavan
Conventional tractor transmission systems feature separate Brake and Bull Cage housings, with brakes often being proprietary components and Bull Cage designed by the Original Equipment manufacturer (OE). To optimize design and performance, an innovative integrated system was developed, combining an in-house braking system with a unitized Bull Cage assembly. This robust design reduces part count, eliminates proprietary dependency (except for friction liners), and enhances performance. Virtual simulations performed under RWUP conditions demonstrated enhanced strength and stiffness in the integrated design. In this Integrated Brake & Bull Cage assembly (IBCA), the braking layout was reconfigured from a 4+1 friction design to a 3+2 configuration which improved balancing, enhancing customer braking experience and increasing contact area by 11%. This adjustment extends friction liner life and boosts mechanical advantage by 7.9%, significantly improving tractor stability and performance
Dumpa, Mahendra ReddyDhanale, SwapnilPerumal, SolairajGomes, MaxsonRedkar, DineshSavant, KedarnathV, Saravanan
The Electrohydraulic Brake Valve (EBV) is a vital component in full-power brake systems for heavy-duty and off-highway vehicles, providing precise hydraulic pressure modulation through electrical control. Traditionally, EBV housings are manufactured using bar-machined components, which offer durability but contribute significantly to the overall weight and cost of the assembly. In response to increasing demands for lightweight and cost-effective solutions, this study presents a targeted design optimization of the EBV housing. The redesigned housing adopts a casting-based geometry, integrates sensor ports for pressure monitoring, and includes a nameplate mounting provision for customer identification. Material substitution and structural simplification were employed to enhance manufacturability and performance. Finite Element Analysis (FEA) was used to validate the mechanical integrity of the new design under operational conditions. The optimized EBV assembly achieved a weight reduction
R, Thangarajan
The Automobile Life Extender (ALE) comprises an on-board function, a machine learning model operating via cloud computing and a smartphone app. The on-board function receives signals such as engine RPM, throttle position, brake pedal position, and hydraulic pressure from the vehicle's ECUs. Based on this data, the on-board ALE module calculates the engine load, brake circuit load, etc., and sends it to the predictive maintenance model via the on-board IoT system. The predictive maintenance model contains recorded data about the type of engine, brake system, and their performance curves acquired from tests conducted by its OEM. Machine learning models holds a crucial role in dynamically analyzing vehicle data, identifying drive patterns, and predicting the need for maintenance of a part or system. A hybrid approach of training models based on supervised and unsupervised learning is incorporated, creating an active learning strategy to maximize the use of available data. Amazon SageMaker
Sundaram, RameshselvakumarKumar, LokeshSaint Peter Thomas, EdwinSureshkumar, SrihariMuthukumaran, ChockalingamMenon, Abhijith
The recently increasing global concern about sustainability and greenhouse gas emission reduction has boosted the diffusion of electric vehicles. Research on this topic mainly focuses on either re-designing or adapting most conventional vehicle subsystems, especially the propulsion motor and the braking components. In this context, the present work aims to model, analyze, and compare three-braking system layouts design alternatives focusing on their contribution to vehicle performance and efficiency: a commercial vacuum-boosted hydraulic braking system, a commercial integrated electrohydraulic braking system, and a concept distributed electrohydraulic brake system. Braking systems performance are evaluated by simulating key maneuvers adopting a full model of a battery electric vehicle (BEV), which includes all relevant components like tires, and powertrain dynamics, which is validated against real-world data. Implementation and integration of the first two systems are discussed
Savi, LorenzoGarosio, DamianoFloros, DimosthenisVignati, MicheleTravagliati, AlessandroBraghin, Francesco
The electrification of transportation is revolutionizing the automotive and logistics sectors, with electric vehicles (EVs) assuming an increasingly pivotal role in both passenger mobility and commercial activities. As the adoption of EVs rises, the necessity for precise range estimation becomes essential, especially under diverse operational circumstances, including vehicle and battery characteristics, driving conditions, environmental influences, vehicle configurations, and user-specific behaviors. Among the varying factors, a key fluctuating one is user behavior—most notably, increased payload, which significantly affects EV range. A key business challenge lies in the significant variability of EV range due to changes in vehicle load, which can affect performance, operational efficiency, and cost-effectiveness—especially for fleet-based services. This research aims to tackle the technical deficiency in forecasting electric vehicle (EV) range under various payload conditions
Khatal, SwarajGupta, AnjaliKrishna, Thallapaka
A significant contributor to particle mass (PM) emissions originating from road transport are particles emitted from brakes, which in Europe are considered in the upcoming Euro 7 emission legislation. UN-GTR (United Nations Global Technical Regulation) no. 24 describes the methodology for measuring brake particle emissions in a test cell setting with a dynamometer, both in terms of PM and PN (particle number). A regulation-compliant test fulfills various quality criteria for different control parameters, which can often be met by applying different control strategies. In this study, we evaluate the effects of implementing different control strategies for torque applied to the brake by the dynamometer, as well as for sampling flow. Additionally, we discuss the cost-saving potential of increasing the automation degree of testing, as well as modifying existing testbeds to accommodate brake emission testing. The torque control strategies applied in this study did not influence PN or PM
Martikainen, SampsaWeidinger, ChristophHuber, Michael Peter
In recent years, the automotive industry has been looking into alternatives for conventional vehicles to promote a sustainable transportation future having a lesser carbon footprint. Electric Vehicles (EV) are a promising choice as they produce zero tail pipe emissions. However, even with the demand for EVs increasing, the charging infrastructure is still a concern, which leads to range anxiety. This necessitates the judicious use of battery charge and reduce the energy wastage occurring at any point. In EVs, regenerative braking is an additional option which helps in recuperating the battery energy during vehicle deceleration. The amount of energy recuperated mainly depends on the current State of Charge (SoC) of the battery and the battery temperature. Typically, the amount of recuperable energy reduces as the current SoC moves closer to 100%. Once this limit is reached, the excess energy available for recuperation is discharged through the brake resistor/pads. This paper proposes a
Barik, MadhusmitaS, SethuramanAruljothi, Sathishkumar
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in torque management, with several ADAS features being an integral part of the EVs/xHEVs. It demands high-fidelity physical and control model exchanges between electric chassis, ride-handling, tire modelling, steering assist, powertrain, and validation using a 0D–1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through co-simulation. The co-simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicles that require detailed modelling of
Eruva, PatrickxavierSarapalli Ramachandran, RaghuveeranChougule, SourabhNatanamani-Pillai, Siva SubramanianScheider, ClementLeclerc, CedricNatarajasundaram, Balasubramanian
Accurate range estimation in battery electric vehicles (BEVs) is essential for optimizing performance, energy efficiency, and customer expectations. This study investigates the discrepancies between physical test data and simulation predictions for the BEV model. A detailed range delta analysis identifies key contributors to the observed deviations, including regenerative braking inefficiencies, increased propulsion demand, auxiliary loads, and estimated drivetrain losses within the Electric Drive Module (EDM) during traction and regen. Results indicate that the test vehicle exhibits lower regenerative braking efficiency, higher traction forces and lower regen energy than predicted by simulations, primarily due to EDM inefficiencies and friction brake usage during regeneration. The study underscores the importance of refining simulation methodologies by integrating real-world, test based EDM loss maps to improve accuracy and better align predictive models with actual vehicle
Mahajan, PrasadKesarkar, SidheshAli, Shoaib
Nowadays, vehicle enthusiasts often vary the driving patterns, from high-speed driving to off-roading. This leads to a continuous increase in demand for four-wheel drive (4WD) vehicles. A 4WD vehicle have better traction control with enhanced stability. The performance and reliability of 4WD vehicles at high speeds are significantly influenced by driveline stiffness and natural frequency, which are largely affected by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and the propeller shafts to enhance the vehicle performance at high speeds. The analysis begins with a comprehensive study of factors affecting the power transfer path, transfer case stiffness, and critical frequency, including material properties, propeller shaft geometry, and different boundary conditions. Advanced computational methods are employed to model the dynamic behavior of the powertrain, identifying the natural frequency of the transfer case and propeller
Kumar, SarveshYadav, SahdevS, ManickarajaSanjay, LKanagaraj, PothirajJain, Saurabh KumarDeole, Subodh M
Overloading in vehicles, particularly trucks and city buses, poses a critical challenge in India, contributing to increased traffic accidents, economic losses, and infrastructural damage. This issue stems from excessive loads that compromise vehicle stability, reduce braking efficiency, accelerate tire wear, and heighten the risk of catastrophic failures. To address this, we propose an intelligent overloading control and warning system that integrates load-sensing technology with real-time corrective measures. The system employs precision load sensors (e.g., air below deflection monitoring via pressure sensors) to measure vehicle weight dynamically. When the load exceeds predefined thresholds, the system triggers a multi-stage response: 1 Visual/Audio Warning – Alerts the driver to take corrective action. 2 Braking Intervention – If ignored, the braking applied, immobilizing the vehicle until the load is reduced. Experimental validation involved ten iterative tests to map deflection-to
Raj, AmriteshPujari, SachinLondhe, MaheshShirke, SumeetShinde, Akshay
Brake response time in truck air brake systems is crucial for ensuring safety and operational efficiency. This paper details the development of a simulation model aimed at fulfilling all regulatory requirements for brake response time, as well as serving as a tool for stopping distance calculations. The actual pneumatic circuit, including brake valves, relay valves, brake chambers, and plumbing have been replicated. The aim is to use 1D simulations to predict the response time compliance during the pressurizing phase (when brakes are applied) of the brake system. A mathematical model is developed using a commercially available 1D simulation tool. This model employs a lumped parameter approach for the pneumatic components, with governing equations derived from compressible flow theory and empirical valve flow characteristics. The simulation outcomes provide detailed response time and pressure build-up profiles. Validation against 201 vehicle test cases showed 96% of simulations within
Kumbar, PrafulMurugesan, KarthikShannon, Rick
Special vehicles such as off-road vehicles and planetary rovers frequently operate on complex, unpaved road surfaces with varying mechanical parameters. Inaccurate estimation of these parameters can cause subsidence or rollover. Existing methods either lack proactive perception or high precision. This article proposes a fusion framework integrating a visual classifier and a dynamics observer for stable, accurate estimation of road surface parameters. The visual classifier uses an adaptive segmentation system for unpaved roads, leveraging a large-scale vision model and a lightweight network to classify upcoming road surfaces. The dynamics observer employs an online wheel-–ground interaction model using stress approximation, integrating strong tracking theory into an unscented Kalman filter for real-time parameter estimation. The fusion framework performs integration of the classifier and observer outputs at data, feature, and decision levels. An adaptive fading factor and recursive
Zhang, ChenhaoXia, GuangZhang, YangZhou, DayangShi, Qin
In agricultural tractors, braking actuation is usually done through control linkages consisting of a series of connected four-bar linkages with multiple pivots from the pedal to the brake pads. The quality of force transmission is critical as it directly affects the braking performance of the tractor. Forces measured at the end of the control linkage or brake pull rod often show deviation from theoretical values based on mechanical advantage calculations. This is due to various factors such as linkage transmission angle, elasticity, and friction losses in joints. A standardized simulation method needs to be developed and validated to predict the losses in the control linkage system. In this paper, the author proposes a simulation approach using multi-body dynamics, which includes contribution factors such as transmission angle, linkage elasticity, and friction in joints. MBS models for brake linkage systems for three different tractors were developed with flex bodies using ADAMS/View
Subbaiyan, Prasanna BalajiNizampatnam, BalaramakrishnaRedkar, DineshArun, GK, VinothR, SengottuPaulraj, Lemuel
Indian passenger car accident data indicates that approximately 44% of crashes are frontal impacts (Refer fig 1). Among the injuries sustained in these crashes, lower leg injuries are notably critical, contributing to nearly 25% of driver occupant injuries (Refer fig 2). To evaluate such injuries, the Bharat New Car Assessment Program (BNCAP) includes lower leg injury metrics as part of the Frontal Offset Deformable Barrier (ODB64) test. While the overall injury performance is assessed at the vehicle level, BNCAP also monitors vehicle interior intrusions—particularly pedal intrusions—as key contributors to lower limb injury severity. A major challenge in frontal crashes is the intrusion of the vehicle's front-end structure into the occupant compartment. Rigid components, particularly the brake pedal assembly, can be displaced rearward during a crash, significantly increasing the risk of lower leg injuries. Therefore, minimizing pedal intrusions into the driver foot-well is critical for
Shetti, Rahul R.Kudale, ShaileshNaik, NagarajBisen, BadalKotak, VijayDudhewar, SwapnilBhagat, AmitDurgaprasad, HNV
As the brain and the core of the electric powertrain, the traction inverter is an essential part of electric vehicles (EVs). It controls the power conversion from DC to AC between the electric motor and the high-voltage battery to enable effective propulsion and regenerative braking. Strong and scalable inverter testing solutions are becoming more essential as EV adoption rises, particularly in developing nations like India. In India, traditional testing techniques that use actual batteries and e-motors present several difficulties, such as significant safety hazards, inadequate infrastructure, expensive battery prices, and a shortage of prototype-grade parts. This paper presents a comprehensive approach for traction inverter validation using the AVL Inverter TS™ system incorporating an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology. It enables safe, efficient, and reliable testing eradicating the need for actual batteries or mechanical
Mehrotra, SoumyaChhabra, Rishabh
In its conventional form, dynamometers typically provide a fixed architecture for measuring torque, speed, and power, with their scope primarily centered on these parameters and only limited emphasis on capturing aggregated real-time performance factors such as battery load and energy flow across the diverse range of emerging electric vehicle (EV) powertrain architectures. The objective of this work is to develop a valid, appropriate, scalable modular test framework that combines a real-time virtual twin of a compact physical dynamometer with world leading real-time mechanical and energy parameters/attributes useful for its virtual validation, as well as the evaluation of other unknown parameters that respectively span iterations of hybrid and electric vehicle configurations, ultimately allowing the assessment of multiple chassis without having to modify the physical testing facility's test bench. This integration enables a blended approach, using a live data source for now, providing
Kumar, AkhileshV, Yashvati
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technologies to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium and subsequently Ferritic Nitrocarburize (FNC) the disc. The Niobium addition will improve the wear resistance of the FNC case, reducing wear debris. The test methodology included: 1. Manufacture of disc samples alloyed with Niobium, 2. Finish machining and ferritic nitrocarburizing and 3. Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3
Barile, BernardoHolly, Mike
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin PrakashRajappan, Dinesh KumarR, SureshN, Gopi Kannan
The performance of passenger vehicle parking brake cables is critical for ensuring vehicle safety and functionality. Vehicle manufacturer evaluates the robustness of cable performance at different road gradient conditions. Effort and stroke performance are among the key parameters for evaluating cable performance. While parking brake system should be designed to minimize effort losses through the cable routing, packaging constraints often prevent it. Excessive losses within the parking brake system, particularly in cable force transmission, can lead to insufficient braking force and may cause vehicle slippage when parked on an inclined surface or non-level terrain. Therefore, it is essential to estimate the losses through cable routing and optimize parameters of the parking brake cable system. Currently, the methods used for evaluating cable performance are either experimental or empirical based. CAE methods using finite element analysis (FEA) and multibody dynamic approaches are
Iqbal, ShoaibSabri, SalahSiddiqui, Arshad
Agricultural operations in hilly, uneven & slopy terrains demands high levels of operator focus, effort and skill. However, todays farming ecosystem across the globe is affected by 2 major scenarios: the aging workforce in the agricultural sector and the ever-growing problem of distraction due to mobile device and social media use. These issues compromise safety during operations such as start stop maneuvers, parking on slopes, and maneuvering in confined & narrow areas. Stringent emission norms are also being mandated across developed and developing countries as a measure to reduce Global Greenhouse house gas emissions. These measures are indeed necessary for sustainability but has increased overall tractor purchase and operating costs without improving safety & operator comfort. There has been a trend seen around the world in terms of poor sales post Emission implementation. Registration of Older tractors without these stringent emission norms were also witnessed in Developed
M, RojerT, GanesanP, VelusamyNatarajan, SaravananV, Mathankumartripathi, ShankarNarni, KiranHaldorai, RajanDevakumar, Kiran
Predictive maintenance is critical to improving reliability, safety and operational efficiency of connected vehicles. However, classic supervised learning methods for fault prediction rely heavily on large-scale labeled data of failures, which are difficult to obtain and maintain a manually built dataset of failure events in real automotives settings. In this paper, we present a novel self-supervised anomaly detection model that makes predictions on the faults without the need for labeled failures by using only the operational data when the systems or robots are healthy. The method relies on self-supervised pretext tasks, like masked signal reconstruction and future telemetry prediction, to extract nominal multi-sensor dynamics (i.e., temperature, pressure, current, vibration) while jointly minimizing the deviation between encoded/decoded signals and normal patterns in the latent space. A unsupervised anomaly detection model is then used to detect when the learned patterns are violated
Kumar, PankajDeole, KaushikHivarkar, Umesh
Items per page:
1 – 50 of 5460